Concrete, masonry, and steel construction



March 1934. J. J. OREILLY CONCRETE, MASONRY, AND STEEL CONSTRUCTION Filed Nov. 27, 1928 2 Sheets-Sheet 1 March 27, 1934. J. J. OREILLY CONCRETE, MASONRY, AND STEEL CONSTRUCTION Filed Nov. 27, 1928 2 Sheets-Sheet 2 r w %9 W Patented Mar. 27, 1934 PATENT OFFICE CONCRETE, MASONRTZ'AND STEEL CONSTRUCTION John James OReilly, Woodside, N. Y.

Application November 27, 1928, Serial No. 322,285

20 Claims.

This invention relates to improved structural members and has for its primary object to provide a very simple and serviceable means whereby said improved structural members may be manufactured and incorporated in a building structure in large quantities on a very economical basis.

It is a more particular object of my invention to provide a box like metal member open on two opposing sides, said sides to correspond to the top and the bottom of the member during the process of manufacturing, and to treat said-memher with fire-proofing and decorative materials before its incorporation in a building structure.

My invention also contemplates placing a large number of the aforesaid boxlike members in spaced arrangement on a platform to form a superunit, or an exact pattern or bond, to an exact full size detail, of architectural stonework, and thus provide a very economical method of applying fireproofing and decorative "materials for a complete wall or the facade of a building of any'size, or for large quantities of interior partitions, floors, etc., virtually without the use of temporary forms.

Another object of my invention isto provide an open half joint all around the edges of every unit or superunit to facilitate field erection and fastening by welding. I

A still further object of my invention is to provide a wall, composed of a lattice of the boxlike metal members, relying entirely upon the aforesaid boxlike metal members for structural value, and cast or plastered materials for fireproofing and decorative purposes.

With the above and other objects in view the invention consists in the improved structural members, and in the form, construction, relative arrangements and manufacturing processes of the several parts as will be hereinafter more particularly described, illustrated in the accompanying drawings, and subsequently incorporated in the subjoined claims.

In the drawings in which I have shown several practical embodiments of my invention:

Figure #1 is an isometric view of the boxlike metal member before treating same with fireproofing or decorative materials.

Figure #2 is a plan View of Figure #1.

Figure #3 is a horizontal sectional view of Figure #2 along the dotted line AA after the boxlike metal member has been treated with fireproofing and decorative materials.

Figure #4 shows in the upper half a plan view of a plurality of individual members assembled, to an exact full size detail of a pattern or bond,

and welded together to form a superunit. The lower half is a plan view of the similar superunit after it has been treated with fireproofing and decorative materials. i

Figure #5 is an isometric view of an embodiment of the boxlike metal member.

' Figure #6 is an isometric view of the improved structural member in one stage of manufacture.

Figure #7 is an isometric view of the completed improved structural member.

Figure #8 is an isometric View showing another embodiment of the completed improved structural member.

Figure #9 is a fragmentary vertical sectional view showing the field joining by welding of two improved structural members.

Referring in detail to the drawings and more particularly to Figures #1-2 and 3, the symbols a1, a2, a3, and a4 serve merely to orient the unit in the difierent views and refer to no particular part.

On a flat paper covered platform, indicated by 20, I place the front metal plate P5 with the attached removable screeds indicated by k6, top

and bottom. The plate P5 and the screeds 706 are fastened together by means of the tack welds indicated by W4. Directly opposite on the side indicated by a2, I place a similar metal plate with top and bottom removable screeds. I bind the front and back of the unit together with the ends. Each end is formed of two separate plates P6 each with a removable screed k6. A space or slot, indicated by S is left between the plates to allow for forming a hollow as is more particularly described hereinafter. The welding of the end plates P6 to the front and back plates P5 is indicated by W6.

In Figure #2 I show the arrangement at the external corners of the boxlike metal member to form the open exterior angles indicated by T. These open angles allow for welding the ends of the units together in the field without spoiling the exactness of the bond, or pattern. A plurality of reinforcing rods indicated by L, are fastened to the front and the back of the unit, preferably four such rods being used to each unit.

In Figure #3 the symbol 32 indicates a layer of facing materials which is first placed in the bottom of each unit, 33 indicates a layer of concrete which is cast monolithically over the facing materials (32), 34 indicates a layer of insulating materials, 35 indicates another layer of concrete with the top finish, indicated by 36, cast mono-' lithically over same. When the cast is completely cured the top and bottom screeds 706 are removed from around the top and bottom of the unit by cutting or severing the tack welds W4. It will be understood that in certain cases a bed of dry sand is placed in the center of the cast in lieu of the insulating materials (34) and the slot (S) provides an easy means for washing out this dry bed of sand after the unit has cured thus forming an insulating hollow in the center of each unit.

In Figure #6 I show the unit on its side after the cast has been cured and made ready for stripping the removable screeds. This particular unit also includes a plank form, indicated by F, which was laid on the platform before the casting Was started with a View to obtaining the cutout back shown in Figure #7, and thus enable me to assemble two units at right angles to each other during field erection. It will be understood that ordinarily this plank and the consequent cutout back are not required and that most of the units are made with both faces, indicated by the symbol '7, identical.

In Figure #4 I show the shop assembly of thirty-six single units to form a superunit. Ja Figure #2 indicates the outline of a single unit and J b Figure #4 indicates the outline of a superunit. In forming a superunit the single units are placed together as shown and welded to each other, preferably by electric arc welding, in a true rigid position. The top and bottom joint screeds (706) are entirely omitted in the formation of a superunit except around the outer edge indicated by the outline symbol Jb. The lower part of Figure #4 shows a similar superunit with the application of the fireproofing and decorative materials completed, The joints, indicated by J12, are cut with an ordinary jointing tool and in this case every other joint in the frame, as

' indicated by 3, has been hidden in the final pattern and only the alternate joints of the frame, as indicated by 4:, are marked out in the final pattern with the jointing tool. In this manner I obtain the architectural effect of bonded stone, while retaining the structural value of having continuous lines of metal in both directions. It will be understood that the metal is relied upon for structural value, and that the cast materials are used solely for protecting the metal against corrosion and fire, and for decorative and insulating purposes. It will be further understood that the boxlike metal members may be erected to form a complete structure and then finished off with wire lath (Welded to the metal boXlike members) and plastered materials. It will also be understood that the reinforcement rods (L) are used for the purpose of binding the cast materials to the boxlike members as an incidental part of the material and process and these rods (L) may be entirely omitted.

Figure #7 shows how the welded plates P5 and P6 form a band of metal around each complete improved structural member. This metal band is exactly one half of the given thickness of the joint required for field erection purposes.

In Figure #9 I indicate how two single units or two superunits are placed together in the field and welded to each other through the open joints so formed as indicated by AE.

This field welding may be intermittent or continuous around each unit or super-unit. When the field welding has been completed the open welding joints between the units (AE) are filled with mortar thus completely fireproofing and w'eatherproofing all of the metal and the welding deposits.

It will be understood that the units and the super-units may be joined and welded in a horizontal plane or a diagonal plane in the same general manner as indicated by Figure #9. Thus, an entire structure including walls, floors, partitions and roof may be formed by anyone thoroughly familiar with the art.

The type of welding I prefer to use is commercially known as electric arc welding. The small amount of heat generated by the arc makes it possible to weld through a narrow slit (AE Figure #9) without cracking or marking the stone facing (7). The exact procedure for making a ground contact, inserting a thin wire electrode between the stones, forming an arc and depositing welding beads along adjacent edges of the welding bands (P5 and P6) would be merely a matter of routine to any competent arc welder.

Figure #5 shows four plates, indicated by P5,

welded together (W) to form another embodiment of the single unit. The corner angle, indicated by 12, is here used as a welding base to avoid the need for a fine exactitude in cutting the plates P5. 131, B2, B3 and B4 serve in Figures #5 and 8 to merely orient the views. These units (Figure #5) are filled with cast materials individually, or they are first welded together with other similar units to form a superunit or the complete facade for a building before the filling process. In thefilling process a layer of concrete is first poured into the bottom of the unit or super-unit and allowed to extend or flow and become moulded above the top edge of the metal plates P5; Then a layer of facing materials is cast monolithically over the concrete uniting integrally with same. The completed unit is shown in Fig. #8. The outline and pattern joints of a'single unit (Ja) or of a super-unit (Jb) are fashioned with an ordinary jointing tool. No interior re-inforcement is indicated in the drawings or required. It will be noted that no removable parts are used. Thus, formwork, as it is generally understood is entirely dispensed with. Owing to the unfinished back (7%) even the platform may be dispensed with and the metal boxlike members (Figure #5) may be placed directly on the ground during the process of casting.

It may be readily understood that two improved structural members such as are indicated in Figure #8 may be placed back to back with a slight space between them and welded together to form a double faced hollow unit.

For insulating purposes I prefer to use dry material such as sand, cinders and the like as a permanent insulating core, or to wash out these materials and leave an air space (50:) between the two separate slabs of each unit. However, any other insulating material suitable for the purpose may be used either during the casting process or after the dry materials have been washed out from between the two slabs of the units. M

It should be apparent that the present invention provides a new article of manufacture, namely, a welding band of uniform half joint thickness, generally flexible and containing two separate artificial stones, each of the said stones being generally provided with one outer surfac- -5 ing projecting factory finished beyond the edges of the welding band to form half of a field welding joint and being completely insulated by space or materials from the other stone in the same band. Easy means for fabricating and erecting the stones in any size from small hand set units to large derrick set units for any structural purpose in a building with great, if not universal architectural beauty, flexibility, speed, safety and economy. Incidentally the virtual elimination of all temporary formwork, dangerous scaffolding, dirt and debris, all field fastenings being accomplished without cutting or otherwise damaging the stones factory facings. Providing, also, a natural metal to metal bearing in the field for architectural stonework through forcing the welding bands to fit to each other in the casting process and then erecting them in the same relative position in the field with structural metal extending in straight lines in two directions, and ultimately a light structure of unusual strength, beauty and economy. 7

It may readily be seen from the foregoing description when considered in connection with the accompanying drawings and subjoined claims that the construction, difference and manner of use of the several illustrated embodiments of the present invention will be clearly and fully understood by anyone thoroughly familiar with the art. In view of the very simple working of the improved structural members and their architectural, structural and economic importance they will be of great utility in the construction of all types of structures. I have disclosed herein several forms, differences and embodiments of my improved structural members which I consider of the most practical importance. Nevertheless, it is to be clearly understood that the invention, in view of the wide scope of architectural and structural requirements, may also be exemplified in'numercus other alternative constructions, and I therefore reserve the privilege of adopting all such legitimate changes as may be fairly embodied within the spirit and scope of the invention as claimed.

I claim,

1. The herein described process of constructing architectural reinforced and insulated stones which comprises the relative steps of placing one or more open metal forms on a paper covered platform, spreading a layer of materials suitable for facing the described stones over the said paper in the bottom of each of the said open metal forms, uniting a layer of cementitious backing materials with the back of this bottom layer of facing materials, spreading a layer of insulating materials or dry'sand or the like over this bottom layer of cementitious backing materials, covering the insulating materials or dry sand or the like with a second layer of cementitious backing materials, uniting a second layer of suitable facing materials with the top of the sec ond layer of cementitious backing materials, allowing the cast to cure or set, and finally removing a strip of metal from the top and from the bottom edges of the said open metal forms for field weld ng purposes and also removing any dry sand or the like which may have been used with a view to forming an interior air space for insulating purposes.

2. The herein described process of constructing architectural reinforced and insulated stones which comprises the steps of placing one or more open metal forms on a paper covered platform,

I spreading a layer of materials suitable for facing the described stones over the said paper in the bottom of each of the said open metal forms, uniting a layer of cementitious backing materials to the back of this bottom layer of facing materials and moulding same over and around the spaced metal reinforcement members fastened to the lower interior of the aforesaid open metal forms, spreading a layer of insulating materials or dry sand or the like over this bottom layer of cementiticus backing materials, covering the layer of insulating materials or dry sand or the like with a second layer of cementitious backing materials and moulding same under and around the spaced metal reinforcement members fastened to the upper interior of the aforesaid open metal forms, uniting a second layer of suitable facing materials with the top of the second layer of cementiticus backing materials, allowing the cast to cure or set, and finally removing a strip of metal from the top and from the bottom edges of the aforementioned open metal forms for field welding purposes and also removing any dry sand or the like which may have been used with a View to forming an interior air space for insulating purposes.

3. A building unit comprising two parallel layers of surfacing materials moulded back to back in spaced alignment, metal banding around the side and end edges of the aforesaid layers holding them rigidly in position, and means in the unit for assembling it in precise architectural and structural relation and welded continuity with other similar units to form a structure.

' 4. A building unit comprising two layers of surfacing materials moulded in a welding band, insulating materials completely separating the aforesaid layers of surfacing materials, and means in the unit for assembling same in precise architectural and structural relation and welded continuity with other similar units to form a structure.

5. A building unit comprising two separate layers of surfacing materials moulded in a welding band, spaced re-inforcement members embedded in the aforesaid layers of surfacing materials and having their ends fastened to the said welding band, and means in the unit for assembling same in precise architectural and structural relation and welded continuity with other similar units in a structure.

6. A building unit comprising two separate layers of united facing and backing materials moulded in a welding band, insulating materials completely separating the aforesaid separate layers from each other in the interior of the unit, and means in the unit for assembling it in precise architectural and structural relation and welded continuity with other similar units to form a structure. I

7. A building material comprising two separate layers of united facing and backing materials, metal banding around the side and end edges of the aforesaid layers holding them rigidly in spaced relation, and means in the unit for assembling it in precise architectural and structural relation with other similar units to form a structure.

8. A building unit comprising metal strips forming a side and end edge welding band, facing materials projecting beyond both outer edges of the aforesaid welding band with two separate layers of backing materials moulded in the interior of the aforesaid welding band each layer being united with the back of one of the layers of facing materials, metal re-inforcement embedded in the separate layers of united facing and backing materials and fastened to spaced structural supporting members in the interior of the unit, insulating materials separating the two separate layers of united facing and backing materials from each other, and means in the unit for assembling it in precise architectural and structural relation with other similar units to form a structure.

9. A building unit comprising two layers of metallically re-inforced united facing and backing materials in a welding band, insulating materials separating the aforesaid layers from each other in the interior of the unit, and means in the unit for assembling it in precise architectural and structural relation with other similar units in a structure.

10. A building unit comprising two separate layers of metallically re-inforced materials moulded back to back in spaced alignment, a welding band around the side and end edges of the aforesaid layers with spaced structural sup porting members welded to same, insulating means separating the aforesaid layers from each other in the interior of the unit, and means for assembling the unit in precise relation with other similar units in a structure.

11. A building unit comprising two separate layers of metallically re-inforced materials enclosing a welded structural frame, insulating materials separating the aforesaid layers from each other in the interior of the unit, and means for assembling the unit in precise architectural and structural relation with other similar units in a structure.

12. A building unit comprising two separate slabs of surfacing materials with an intermediary metal frame holding them in spaced alignment, a suflicient exposure of metal on the back of the unit for a right angle connection, and a welding band around the side and end edges of the unit for field fastening purposes. 7

13. A building unit comprising two separate slabs of metallically reinforced surfacing materials with an intermediary frame holding them apart in spaced alignment, a sufficient exposure of metal on the back of the unit for a right angle connection, and a welding band around the side and end edges of the unit for field fastening purposes.

1a. A building unit comprising two separate slabs of metallically reinforced united facing and backing materials with an intermediary frame holding them apart in spaced alignment, insulating materials in the interior of the unit completely separating the two separate slabs from each other, and a sufficient exposure of the aforesaid frame at the side and end edges and the back of the unit for assembling it in any plane and in precise architectural and structural relation and welded continuity with other units to form a structure.

15. A building unit comprising a welded intermediary frame, a plurality of metallically reinforced slabs of united facing and backing materials sheathing the aforesaid frame on two opposite field exposed surfaces, and means in the unit for assembling same in precise architectural and structural relation with other similar units to form a structure.

16. A building unit comprising an intermediary metal frame, a plurality of metallically re-inforced slabs sheathing the aforesaid frame on two opposite field exposed surfaces, and means in the unit for assembling it in precise architectural and structural relation and welded continuity with other units to form a structure.

17. A building unit comprising a plurality of metal bands welded together to form an intermediary frame, a plurality of metallically reinforced slabs sheathing the aforesaid frame on two opposite field exposed surfaces, and means in the unit for assembling it in precise architectural and structural relation with other units to form a structure.

18. A building unit comprising an intermediary frame of welded metal plates, a plurality of slabs sheathing the aforesaid frame on two opposite field exposed surfaces, insulating materials separating the slabs from each other in the interior of the unit, and means in the unit for assembling it in precise architectural and structural relation with other units to form a structure.

19. A building unit comprising an intermediary frame, a plurality of factory finished slabs sheathing the aforesaid frame on two opposite field exposed surfaces, insulating materials separating the slabs from each other in the interior of the unit, and means in the unit for assembling it in precise architectural and structural relation with other units to form a structure.

20. A building unit comprising a welding band and an intermediary frame, a plurality of factory finished slabs sheathing the aforesaid frame on two opposite field exposed surfaces, insulating materials separating the backs of the aforesaid slabs from each other in the interior of the unit, and a sufiicient exposure of metal along the side and the end edges and the back of the unit for assembling it in any plane with respect to other units to form a structure.

JOHN JAMES OREILLY. 

